PM Family Data Sheet
Contents
1. Controller Model PM100DX PM100DZ PM100DXR PM150DX PM150DZ Maximum DC Voltage 360 V 720 V 400 V 360 V 720 V operating Maximum DC Voltage 500 V 900 V 500 V 500 V 900 V non operating Motor Current Continuous 300 Arms 150 Arms 300 Arms 450 Arms 225 Arms Motor Current Peak 350 Arms 200 Arms 450 Arms 450 Arms 300 Arms DC Bus Capacitance 440 uF 280 uF 440 uF 880 uF 560 uF Size See drawing See drawing See drawing See drawing See drawing Weight 7 5 kg 7 5 kg 7 5 kg 10 7 kg 10 7 kg Minimum Conductor Size 4 AWG 2 AWG 4 AWG Maximum Conductor Size 1 AWG 3 0 AWG 1 AWG Minimum Cable O D 9 0 mm 11 0 mm Maximum Cable O D 16 5 mm 21 0 mm The PM100DXR is only available for special applications i e racing use must be approved by RMS Peak current is defined as a maximum of 30 seconds Depending on cable it may be necessary to add additional sleeve to cable to meet the minimum Cable O D of the cable gland Information subject to change without notice 1 5 2012 page 1 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 Power Production and Controller Ratings The mechanical power that can be generated by any motor controller is highly dependent on the motor characteristics It is possible to estimate the actual motor output power you can achieve in any specific system if certain motor characterist2. The CAN terminator for each port can be applied or opened under software control during setup or at any time EMI filtering for common mode and differential mode noise and transient suppressors are used to improve the robustness of the serial I O system Refer to the PM100 CAN Manual for more information on the protocol implemented by RMS RS 232 Serial Interface There is one RS 232 serial interface with EMI filtering This port can be used to set up and tune the controller and to download controller software updates from a computer RMS offers a simple serial user monitor that runs on the PC to allow changing parameters changing the I O functionality to suit the application needs and other user selectable optimizations Encoder Interface For applications that use an incremental optical or magnetic encoder there is a 5V interface to power the external encoder and to receive level translate and filter the signals from A B and INDEX channels The sensor interface is designed to work with an open collector type sensor The maximum frequency of the interface is 50 kHz The DSP has specific hardware for wide dynamic range speed and angle calculation from the encoder data Resolver Interface A resolver can be used in place of the incremental encoder to determine machine rotor position and velocity The resolver is excited by a precision sinusoid and the sine and cosine winding outputs are filtered for noise and presented to the DSP to be digitize
3. multiplying the motor efficiency by the controller efficiency For this example we would multiply 91 2 with 97 giving a system efficiency of 88 5 The DC input power can now be calculated as DC_Power Prnech 885 Voatt Ibat 88 36kW To continue the example the DC current would be 276 amps at 320V battery voltage 88 36kW Vrat General Specifications for the PM Family Description Value Short Circuit Protection Yes Hardware Over current Protection Yes Vehicle System Power 16Vpc 12V Systems Operating Temperature Range coolant water no 40 80 C derating Isolation High Voltage to Low Voltage 1000V ms Isolation High Voltage to Case 1000V ms Isolation Low Voltage to Case 50V Operating Temperature Range coolant water derated 40 105 C output power Non Operating Temperature 40 115 C Storage Temperature 55 105 C Coolant Type 50 50 EGW Coolant Flow Rate 8 12 LPM Coolant Pressure Drop 0 2 bar for PM100xx 0 25 bar for PM150xx Maximum Coolant Pressure above ambient 1 4 bar Operating Shock ISO 16750 3 Test 4 2 2 2 500 m s 50g pending testing Operating Vibration ISO 16750 3 4 1 2 4 Test IV 27 8 m s 38 ms pending testing Environmental Protection Class see ISO 20653 IP6K9K EMC compatibility IEC pending testing Information subject to change without notice 1 5 2012 page 3 of 10 PM FAMILY DATA SHEET RINEHART MO
4. PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tu 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 AC Motor Controller for Electric and Hybrid Vehicles Product Summary The Rinehart Motion Systems LLC RMS PM Family of AC Motor Controllers are designed for on and off road Electric EV or Hybrid Electric HEV applications The motor controller converts the DC power from the vehicle ESS Energy Storage System Battery to the 3 phase AC required by the motor These Traction drives are fabricated using a patented high heat flux thermal design approach that dramatically reduces the size and weight of the finished drive and improves its life in the automotive environment With extensive experience in automotive and military vehicle traction and power electronics applications RMS has achieved a major breakthrough in integrating Motor Control into a vehicle RMS offers several different models within the PM Family of motor controllers to suit the DC bus voltage and motor current requirements of your specific vehicle The PM Family has been designed to operate with many types of motors including Induction Motors IM and Permanent Magnet motors PMSM or IPM Contact RMS for the latest list of motors supported by our controllers The Drive can also be tuned to your new motor contact the factory for more information The primary difference between models in the PM Family is the rated voltage and current ultimate power output
5. TION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 The PM Family of Motor Controllers comes with cable glands designed to accept shielded cable Proper shielding and grounding of the motor controller cables is essential to control EMC that can effect motor operation and potentially other systems on the vehicle The motor controller is designed with a wire clamping system that requires the use of a wire ferrule Refer to the PM Family User s Manual on making the High Voltage Connections to the PM100 RMS recommends Champlain Cable type EXRAD XLE 1000V shielded power cables for use with our products The size of the wire used depends on the application the motor peak and continuous current and how long those peaks are expected to last For reference a size versus ampacity continuous current handling capability chart is copied here Wire Size Ampacity 4 AWG 190 2 AWG 255 1 AWG 293 1 0 AWG 339 2 0 AWG 390 3 0 AWG 451 Each controller contains a significant amount of DC bus capacitance It is necessary for the user to provide a pre charge circuit for this capacitance The PM motor controller does not present any practical limits on how small or large the pre charge current is However the user should take care to design the circuit so that if the controller were to fail shorted the pre charge circuit is not damaged and cannot start a fire Pre charge circuit operation may be con
6. ase 215VAC If the maximum motor rated current is 300 Arms you still can t calculate how much mechanical power you can deliver without knowing the motor Power Factor and efficiency at that operating point It s not just how much current is flowing into the motor but when it flows its phase shift Power Factor represents the 3 phase system phase shift that exists between the motor voltage and the motor current The motor power factor varies from each different motor motor type and operating point For this example assume a motor power factor of 0 768 Motor efficiency will also vary from motor to motor and over the speed torque operating plane Assume motor efficiency is 91 2 typical of an SPM motor at peak load We now have enough information to calculate the motor output power Motor Power 3 Motor Voltage Motor Current Power Factor Efficiency For this example we get Information subject to change without notice 1 5 2012 page 2 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 78 2 kW 3 215 300 0 768 0 912 The DC Input Current to the motor controller is based on the motor input power and the efficiency of the motor controller The motor controller efficiency will vary depending on the load conditions However for most high power conditions a typical efficiency of the PM Family of controllers is 97 The total system efficiency can be found by
7. d at 12b resolution Due to the nature of the resolver interface the resolver excitation frequency is the same frequency as the PWM frequency Hall Sensor Interface A Hall Sensor Interface is provided for motors that use this type of position sensing The interface includes A B C channel inputs as well as providing 5V power for the sensor The sensor interface is designed to work with a open collector type output Low Voltage Signal Connector Interface The PM Family motor controllers use two connectors for the low voltage signals Tyco AMP AMPSEAL family The following connectors are used Connector Connector Type Mating Connector Mating Contact Type Type J1 35 pin Tyco AMP 776231 1 Tyco AMP 776164 1 Tyco AMP 770854 1 J2 23 pin Tyco AMP 776228 1 Tyco AMP 770680 1 Tyco AMP 770854 1 Note It is extremely important for proper operation of the connector to utilize the recommended crimp tool from Information subject to change without notice 1 5 2012 page 6 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 Tyco AMP Tyco AMP part number 58529 1 A connector kit is available from RMS that includes the mating connectors and 60 contacts RMS p n G1 0001 01 The AMPSEAL contact is designed to work with 16 20 AWG wire with an insulation diameter between 1 70 2 70 mm Make sure that the wire used conforms to these requirements Info
8. ics are known A common misconception is that Motor Current times DC Bus Voltage will give the motor power THIS IS INCORRECT First it is important to know the continuous and maximum peak motor current ratings It is possible that the maximum motor current could be higher than the current rating of the motor controller If so then either a higher current controller can be considered or use the motor controller current limits in the below equations The next important item to understand is the maximum motor voltage In many circumstances the maximum motor voltage is limited by the available battery voltage The available motor voltage from the Drive output terminals is a function of the DC bus voltage V pc gt Motor Voltage line to line RMS 5 y For example if the Battery pack voltage is 320V then the motor voltage the inverter can make can never exceed 226 27V ems In practice the actual voltage is generally limited to 95 of this value so for design purposes the maximum motor voltage should be assumed to be 215 0 Vams max As the motor speed varies the Drive will vary its output voltage to deliver the required power until it reaches this hard limit due to the battery voltage You can t get any more To go faster the motor has to enter field weakening where the Drive adds current to defeat some of the permanent magnet field so the motor output voltage is reduced and stays below the hard limit in this c
9. rmation subject to change without notice 1 5 2012 page 7 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tu 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 Outline Drawings PM100 Package Outline N JIC 6 STANDARD HOSE END FITTING WATER ETHYLENE GLYCOL PORTS Information subject to change without notice 1 5 2012 page 8 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tu 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 PM150 Package Outline AN 6 JIC 6 STANDARD HOSE END FITTING WATER ETHYLENE GLYCOL PORTS 2PLCS Information subject to change without notice 1 5 2012 page 9 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 Contacts SALES USA SALES ASIA Contact Rich Swortzel Contact Dr Steve Shi New Eagle Business Development Eontronix Co Ltd rswortzel neweagle net steve shi eontronix com 734 649 8156 Voice 734 330 3800 Voice 928 395 2114 Fax 734 468 4085 Fax www neweagle net www eontronix com FACTORY Rinehart Motion systems info rinehartmotion com 503 344 5085 Voice 503 682 9014 Fax www rinehartmotion com Information subject to change without notice 1 5 2012 page 10 of 10
10. trolled by the internal software refer to the PM100 User s Manual for more information Control Software The PM Family of motor controllers comes with advanced motor control software developed by RMS This software includes many features that are useful for control of an electric motor in an EV Hybrid application There is a rudimentary Vehicle Controller simplistic VCU functionality in the drive that may be enabled to operate the attached motor on the bench or to drive a prototype vehicle around the parking lot in system integration However most safety sertified applications use the PM Drive as a CAN based output node a separate computer the VCU issues torque commands and reads feedback from the motor and the battery management system the driver inputs etc over the CAN serial port For more information on the software refer to the PM100 User s Manual The PM Family of Drives can also be programmed with custom software or with customer developed software Contact RMS for more information Information subject to change without notice 1 5 2012 page 4 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 Hardware Description The following section provides a brief description of the I O hardware features of the PM family of motor controllers To use these I O features please refer to the PM100 Users Manual Feature Summary Fea
11. ture Generation 2 Generation 3 Analog Inputs 0 5V 4 6 RTD Inputs 2xPT100 2xPT100 PT1000 2xPT100 Selectable Digital Inputs 6 8 High Side Outputs 2 4 Low Side Outputs 2 2 Resolver Interface Yes Yes Quadrature Encoder Interface Yes Yes Hall Effect Sensor Interface No Yes CAN Interface Yes Yes RS 232 Interface Yes Yes The PM150 family is implemented with Generation 3 Features The PM100 family is currently implemented with Generation 2 Features The PM100 family is expected to change to Generation 3 in Spring of 2012 Analog Inputs Intended for general analog signal sensing 0 5V RTD Inputs Used to sense temperature Digital Inputs Intended for general interface to the vehicle and for feedback from external contactors and switchgear as required in the application There are two types of inputs Switch To Ground and Switch To Battery Refer to the user s manual for more detail High Current Digital Outputs High side outputs can be used for driving 12V loads Low side Outputs Low side outputs can be used for driving 12V loads that switch the ground side of the load Information subject to change without notice 1 5 2012 page 5 of 10 PM FAMILY DATA SHEET RINEHART MOTION SYSTEMS LLC tm 7929 SW Burns Way Suite B Wilsonville OR 97070 503 344 5085 CAN Interface There are two CAN2 0B compliant serial ports capable of operation at 100k 250k 500k and 1Mb sec by software selection
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